Cutting force modeling and simulation of tee slot milling

Based on the geometrical model of a tee slotting cutter, the coordinates of the cutting edge along each cutting flute are mathematically expressed. The instantaneous un-deformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration so that the dynamic regeneration effect is taken into account. A numerical method is employed to solve the differential equations governing the dynamics of the milling system and a chatter detection criterion is applied to the simulated data to determine the stability of a milling process. As a result, the cutting force, tool tip vibration and stability limits of a milling process are predicated. A Matlab-based simulation system for predicating cutting forces in tee slot milling is developed using the model. Cutting tests have been conducted to verify the simulation system.